Predictive refractory performance measurement system

ABSTRACT

A measurement system is provided for predicting a future status of a refractory lining that is lined over an inner surface of an outer wall of a manufacturing vessel and exposed to an operational cycle during which the refractory lining is exposed to a high-temperature environment for producing a non-metal and the produced non-metal. The system includes one or more laser scanners and a processor. The laser scanners are configured to conduct one or more pre-operational laser scans of the refractory lining prior to the operational cycle to collect data related to pre-operational cycle structural conditions, and one or more post-operational laser scans of the refractory lining after the operational cycle to collect data related to post-operational cycle structural conditions of the refractory lining. The processor is configured to predict future status of the refractory lining after subsequent operational cycles based on the determined exposure impact of the operational cycle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/089,005, filed Nov. 4, 2020, which is a continuation-in-part of U.S.application Ser. No. 16/583,377, filed Sep. 26, 2019, said patentapplication herein fully incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to refractory analysis and, morespecifically, a system and method for predicting refractory performance.

BACKGROUND OF THE INVENTION

Industrial processes, such as production of steel and other processesassociated with high-temperature erosive environments in manufacturingvessels, are supported by ever-increasing collections of process dataand parameters. Many statistical, analytical, and data manipulationsolutions can be used to quickly and efficiently analyze process datawith the aim of process optimization and improved efficiencies. Processoptimization systems, composed of computing system hardware andsoftware, collect the raw process data and correlate the raw processdata with changes, modifications, or upgrades to the process. Thesystems are capable of time stamping and correlating various collecteddata. In advanced formats, the systems are also capable of analyticaland statistical correlations of multiple and interdependent parameters.Using these correlations, the systems can describe the influences on theprocess efficiencies. Many of the collected process parameters,individually or in correlations, directly influence the performance ofthe refractory linings.

Such systems, as described above, are used in processes making liquidsteel in primary melting units, such as basic oxygen furnaces andelectric arc furnaces. The systems can also be used with processes insecondary refining and transport vessels, such as steel ladles,degassers, argon oxygen decarburization, vacuum oxygen decarburizationfurnaces, or similar. Vessels that contain liquid steel must containlinings constructed from high temperature refractory materials resistantto liquid steel and molten slags. Even so, both liquid steel and moltenslags serve to corrode the refractory linings.

In addition, systems as those described above can be used in processesmaking glass, cement, lime, or other minerals, and in other hightemperature units, such as incinerators and others. Further systems canalso be used in production and refinement of oils, gasses, chemicals, orsimilar materials. Vessels utilized in processes that operate at hightemperatures, such as continuous and batch glass melters, cement or limerotary and shaft kilns, or rotary and shaft kilns processing otherminerals, or preheat towers and coolers, or various petrochemicalreformers, such as primary and secondary ammonia reformers, or fluidcatalytic cracking units, or thermal reactors, such as Sulphur recoveryunits, or gasifies, fluidized beds, incinerators and the like mustcontain linings constructed from high temperature refractory materialsresistant to corrosive and erosive conditions or non-metallic liquids ormolten slag or coatings. Even so, all of the above conditions serve tocorrode the refractory linings.

The level and the progression of the refractory lining corrosion areconventionally measured by three widely accepted and currently employedmethods: visual observation, infrared mapping, and laser scanning.Visual observation of refractory lining corrosion can be performedduring servicing of the refractory linings. Visual observation ofrefractory lining corrosion can also be performed by physicalmeasurement of the refractory lining remnants after completion of theuseful life of the refractory lining. The level and the progression ofthe refractory lining corrosion in glass melters can also be measured byradar detections.

Infrared mapping of refractory lining corrosion is performed on theoutside surfaces of the lining-equipped vessels that are loaded withliquid steel, glass, cement, lime, oils, gases, chemicals, or otherminerals or materials at a specific step or time at which liquid steel,glass, cement, lime, oils, gases, chemicals, or other minerals ormaterials are respectively in contact with the vessels. The purpose ofinfrared mapping of refractory lining corrosion is to correlate thetemperature of the outside surfaces of the loaded vessels with theconditions of the refractory linings installed in the vessels. Infraredmapping can be as simple as a visual review of infrared mapping images.Visual review of infrared mapping images can be additionallycomplemented with software manipulations, advanced temperature imagery,and data reports.

Laser scanning of refractory lining corrosion is performed on insidesurfaces of empty, in some cases on full or partially full,lining-equipped vessels at a specific process location. The laserscanning systems can utilize multiple types of hardware and devicestherein, including, but not limited to, laser time-of-flight cameras. Asoftware package capable of processing point cloud data into fullygeometrically descriptive images and generating various data reports canbe used to analyze the data collected from the laser scanning. Thepurpose of the method is to measure, within an accuracy of 2 mm, anactual geometry, a remaining thickness, or other detailed parameters ofthe refractory lining. With respect to liquid steel, such parameters mayinclude, but are not limited to, a condition of functional parts of theladle, such as a well block or a taphole, or a sanding efficiency of thewell blocks or tapholes, or measure a steel yield trapped in thedepressions of the bottom of the ladle, or conditions of the passages ofthe flow control components, which may include, but are not limited to,slide gates. With respect to glass, cement, lime, oils, gases,chemicals, or other minerals or materials, such parameters may include,but are not limited to, a condition of functional parts of therespective vessel in contact therewith, such as, but not limited to,entry or exit ports, crowns, roofs, or specific functional sections.

Radar waves can be used for measuring the thickness of the refractorylining in a glass melter during the operation thereof by determining,based on a response of the radar waves, whether the radar waves enteredareas having differing densities. The radar measurement is performedfrom an outer surface of the glass melter.

Conventionally, the four methods described above are utilizedindependently of each other. The refractory lining corrosion isprimarily identified in industrial processes by visual observation.However, infrared mapping, radar scanning, and laser scanning areconsidered alternate and independent solutions for refractory liningscorrosion evaluation. In fact, the four methods compete in themarketplace at significantly diverging costs. The costs of visualobservation are largely related to overhead. Infrared mapping systemsand radar scanning systems, in glass melters, are less costly than laserscanning systems.

However, the use of the methods individually may have drawbacks incertain situations. For example, very infrequent visual observation ofrefractory lining corrosion does not collaborate with actual conditionsof the refractory linings physically described using laser scanningafter each heat or process cycle, or, to a lesser extent, infraredmapping. Further, visual observation does not allow for the collectionof valuable process optimization data that can be used to calculatepredictive performance of the refractory lining.

Infrared mapping of refractory lining corrosion is indirect and judgesthe conditions of the refractory lining by observation of the outsidesurfaces. The temperature readings collected by the infrared mappingmethod are influenced by the flow of heat thru the actual thickness ofthe lining. However, adversely, the temperature readings are alsoinfluenced by the temperature of the liquid steel or the temperature ofimpregnated lining voids by liquid steel, process liquids, gasses,solids, or molten slag or coatings. Such impregnations are common andcould generate false readings using infrared mapping, thereby leading toa premature replacement of a refractory lining at a significant cost.

Laser scanning of refractory lining corrosion is direct and measures theactual conditions and thickness of the refractory lining with highprecision. However, laser scanning is incapable of measuring thethickness and conditions of the refractory lining if the refractorylining is coated by slags or coatings at the time of measurement. Inother words, liquid steel, or other melts such as glass or molten slagsor coatings cannot be present within the ladle or vessel if accurateresults from laser scanning are to be desired. Laser scanning in thosesituations can only measure the actual conditions and thickness ofvisually exposed parts of the refractory linings, such as glass meltercrowns. If a significant flaw in the lining, such as a large crack orinsufficient thickness, were covered by the temporary slag coating, thelaser scan would generate false reports. The coating could then meltaway during operation, thereby exposing the hidden refractory liningflaw to liquid steel or a high temperature process environment involvingnon-metals. This could lead to a catastrophic breach of the refractorylining.

In addition, radar scanning in glass applications is within an accuracyof 5 mm and lower than the high precision of laser scanning. Further,each point must be measured individually in radar scanning. As such,radar scanning is time consuming. Only so many points—typically not morethan 150—can be completed throughout the entire scan of the vessel.Similar to infrared cameras, radar scanning cannot distinguish betweenthe glass melt or glass infiltrations and can give false readings ifsuch infiltrations are behind the refractory lining.

The present invention has been developed to address these and otherissues by providing a system by which refractory lining corrosion isidentified through both laser scanning and infrared mapping, andpossibly, in the case of glass melters, radar scanning. In addition, thepresent invention provides a system in which process characteristics andvariables can be used in addition to the data retrieved by laserscanning, infrared mapping, and radar scanning to predict the futureperformance of the refractory lining in question.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the present invention, there isprovided a measurement system for predicting a future status of arefractory lining that is lined over an inner surface of an outer wallof a manufacturing vessel and exposed to an operational cycle duringwhich the refractory lining is exposed to a high-temperature environmentfor producing a non-metal and the produced non-metal. The systemincludes one or more laser scanners and a processor. The laser scannersare configured to conduct one or more pre-operational laser scans of therefractory lining prior to the operational cycle to collect data relatedto pre-operational cycle structural conditions, and one or morepost-operational laser scans of the refractory lining after theoperational cycle to collect data related to post-operational cyclestructural conditions of the refractory lining. The processor isconfigured to determine an exposure impact of the operational cycle onthe refractory lining by comparing the collected pre-operational cyclestructural condition data with the collected post-operational cyclestructural condition data, and predict the future status of therefractory lining after one or more subsequent operational cycles basedon the determined exposure impact of the operational cycle.

In accordance with another embodiment of the present invention, there isprovided a method of predicting a future status of a refractory liningthat is lined over an inner surface of an outer wall of a manufacturingvessel and exposed to an operational cycle during which the refractorylining is exposed to a high-temperature environment for producing anon-metal and the produced non-metal. The method includes conducting oneor more pre-operational laser scans of the refractory lining prior tothe heat, the conducting prior to the operational cycle to collect datarelated to pre-operational cycle structural condition, conducting one ormore post-operational laser scans of the refractory lining after theoperational cycle to collect data related to post-operational cyclestructural conditions of the refractory lining, determining, via aprocessor, an exposure impact of the operational cycle on the refractorylining by comparing the collected pre-operational cycle structuralcondition data with the collected post-operational cycle structuralcondition data, and predicting, via the processor, the future status ofthe refractory lining after one or more subsequent operational cyclesbased on the determined exposure impact of the operational cycle.

These and other advantages will become apparent from the followingdescription of a preferred embodiment taken together with theaccompanying drawings and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may take physical form in certain parts and arrangement ofparts, a preferred embodiment of which will be described in detail inthe specification and illustrated in the accompanying drawings whichform a part hereof, and wherein:

FIG. 1 is a schematic view illustrating a first example predictiverefractory performance measurement system of the present invention;

FIG. 2 is a schematic view illustrating a first example of a refractorylining being respectively lined over an inner surface of an outer wallof an empty metallurgical vessel and a full metallurgical vessel forwhich a future status of the refractory lining is to be predicted by thefirst example predictive refractory performance measurement system ofthe present invention;

FIG. 3 is a flowchart illustrating a first example method of the presentinvention of predicting a future status of a refractory lining, wherethe refractory lining is lined over an inner surface of an outer wall ofa ladle vessel and exposed to a heat during which the refractory liningis exposed to molten metal;

FIG. 4 is a schematic view illustrating a second example predictiverefractory performance measurement system of the present invention;

FIG. 5 is a schematic view illustrating an example of a refractorylining being respectively lined over an inner surface of an outer wallof a manufacturing vessel for which a future status of the refractorylining is to be predicted by the second example predictive refractoryperformance measurement system of the present invention; and

FIG. 6 is a flowchart illustrating a second example method of thepresent invention of predicting a future status of a refractory lining,where the refractory lining is lined over an inner surface of an outerwall of a manufacturing vessel and exposed to an operation cycle duringwhich the refractory lining is exposed to a high-temperature environmentfor producing a non-metal.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

The following detailed description is provided to assist the reader ingaining a comprehensive understanding of the methods, apparatuses,and/or systems described herein. However, various changes,modifications, and equivalents of the systems, apparatuses and/ormethods described herein will be apparent to one of ordinary skill inthe art. In addition, descriptions of functions and constructions thatare well known to one of ordinary skill in the art may be omitted forincreased clarity and conciseness.

Throughout the drawings and the detailed description, the same referencenumerals refer to the same elements. The drawings may not be to scale,and the relative size, proportions, and depiction of elements in thedrawings may be exaggerated for clarity, illustration, and convenience.

The features described herein may be embodied in different forms and arenot to be construed as being limited to the examples described herein.Rather, the examples described herein have been provided so that thisdisclosure will be thorough and complete, and will convey the full scopeof the disclosure to one of ordinary skill in the art.

Initially, for purposes of the discussion herein, “metallurgical vessel”refers to any container that can be used within the process for theproduction or refining of molten steel. This includes, but is notlimited to, a primary melting unit or second metallurgical vessels. Aprimary melting unit includes, but is not limited to, a basic oxygenfurnace or an electric arc furnace. Secondary metallurgical vesselsinclude, but are not limited to, a ladle metallurgical furnace, adegasser, an argon oxygen decarburization vessel, or a vacuum oxygendecarburization vessel. An example of a secondary steelmaking ormetallurgical vessel that is tasked with carrying molten steel is emptyladle vessel 16 and full ladle vessel 18, which will be described inmore detail in the discussion below. However, embodiments describedherein are not limited thereto, as the use of a metallurgical vessel isnot limited to use with molten steel, but also can hold other moltenmetals in general.

For purposes of the discussion herein, “manufacturing vessel” refers toany container that can be used within the high temperature process forthe production or refining of glass, cement, lime, chemicals, oils andgasses, or other materials typically called as non-metals. Thisincludes, but is not limited to, continuous and batch glass melters,cement or lime rotary and shaft kilns, or rotary and shaft kilnsprocessing other minerals, or preheat towers and coolers, or variouspetrochemical reformers, such as primary and secondary ammoniareformers, or fluid catalytic cracking units, or thermal reactors, suchas sulphur recovery units, or gasifiers, fluidized beds, incineratorsand others. However, embodiments described herein are not limitedthereto, as the use of a manufacturing vessel is not limited to use withglass, cement, lime, chemicals, oils and gasses, but also can hold orprocess other non-metals in general.

Further, steel mill operational parameters that influence theperformance of refractory linings in metallurgical vessels will bedescribed along with, if applicable, the variability and the measuringmethods thereof. For example, for purposes of the discussion herein, a“heat” may refer to one performance of a steel-making process frombeginning to end.

In addition, operational parameters that influence the performance ofrefractory linings in manufacturing vessels will be described alongwith, if applicable, the variability and the measuring methods thereof.For example, for purposes of the discussion herein, an “operationalcycle” may refer to one performance of a manufacturing process frombeginning to end. An “operational cycle” may also refer to a time periodbetween shutdowns, a time period between inspections, a time periodbetween maintenance, a time period between repairs, or a time periodbetween laser scans of the manufacturing vessel.

For purposes of the discussion herein, “scrap or charging mix” withrespect to the process for the production or refining of molten steelcould include batches with specific proportions of individual scrapqualities and iron units for the grade of steel to be produced,including, but not limited to, ferrous scrap identified by guidelinesfrom the Institute of Scrap Recycling Industries, which additionally mayinclude, but is not limited to, heavy melting steel, busheling,clippings, bundles, shreddings, turnings, plates, structures, cast iron,mixed heavy melt, rails, railroad, and can bales, and could becomplemented by other sources of iron units, such as, but not limitedto, pig iron and hot briquetted iron.

With respect to “scrap or charging mix” in the process for theproduction or refining of molten steel, there is a large variability ofsteel scrap qualities and iron units available for the steelmaker toutilize in his primary melting process. Physical attributes of thesematerials, such as size, shape, and contaminations, chemical attributesof these materials, such as composition, rust, and impurities, and acomposition of a “scrap or charging mix” for each heat, have directimpact on the efficiency of the melting process, the duration of therefining metallurgy and the corrosion and erosion of the refractories.The “scrap or charging mix” is typically a simple batching instructionwith specific proportions of individual scrap qualities and iron units.These instructions are based on the availability of charging componentsand grade of steel to be produced.

Further, for purposes of the discussion herein, “charging mix” or“continuously fed mix” with respect to the high temperature process forthe production or refining of glass, cement, lime, chemicals, oils andgasses, or other materials typically called as non-metals couldrespectively include batches or continuous feed with specificproportions of individual raw and starting materials for the grade ofthe non-metal to be produced.

With respect to “charging mix” or “continuously fed mix” in the hightemperature process for the production or refining of glass, cement,lime, chemicals, oils and gasses, or other materials typically called asnon-metals, there is a large variability of qualities available for thenon-metal maker to utilize in the manufacturing process. Physicalattributes of these materials, such as size, shape, and contaminations,along with chemical attributes of these materials, such as compositionand impurities, and additionally a composition and frequency of a“charging mix” or “continuously fed mix” for each operational cycle,have direct impact on the efficiency of the manufacturing process, theduration of the operational cycle, and the corrosion and erosion of therefractories. The “charging mix” is typically a simple batchinginstruction with specific proportions of individual ingredients oradditives. The “continuously fed mix” is typically a feeding instructionwith specific proportions of individual ingredients or additives. Theseinstructions are based on the availability of charging or continuouslyfed mix components and grade of non-metal to be produced.

Moreover, for purposes of the discussion herein, “steel” and gradesthereof could include, but are not limited to, carbon steels, nickelsteels, nickel-chromium steels, molybdenum steels, chromium steels,chromium-vanadium steels, tungsten steels, nickel-chromium-molybdenumsteels, and silicon-manganese steels. Further, each grade of steelrequires some alternation in the processing of the steel in a primarymelting unit, such as, but not limited to, a basic oxygen furnace or anelectric arc furnace, and secondary metallurgical vessels, such as, butnot limited to, a ladle metallurgical furnace, a degasser, an argonoxygen decarburization vessel, or a vacuum oxygen decarburizationvessel. These specific process requirements, aimed at achieving therequired steel grade, have a demonstrated effect on refractory liningperformance. The amount of residual carbon, the level of impurities andthe addition of alloying elements are achieved by decarburization anddeoxidation processes, having distinctive corrosion and erosion effecton refractories.

Additionally, for purposes of the discussion herein, “non-metals” andgrades thereof could include, but are not limited to, glass compositionssuch as soda-lime-silicate container or flat glasses, or soda-silicatewater glasses, or boro-silicate glasses, or other specialty glasses, ora variety of other glass compositions typically called e-glasses,c-glasses, fiberglass, and the like.

Moreover, for example, the grades of cement clinkers are many and havestandardized specifications per ASTM C-150/C-150M-20. The specificationlists five types; Type I is the standard product, also referred to as“ordinary cement”; Type II possesses moderate resistance to sulfateattack, also called moderate-heat cement; Type III ishigh-early-strength cement; Type IV is low-heat cement; and Type V issulfate-resisting cement with appropriate limits on composition. Inaddition, ASTM C1157 lists further modification, such as Type GU forgeneral use, type HE for having high early strength, type MS for havingmoderate sulfate resistance, type HS for having high sulfate resistance,type MH for having moderate heat of hydration, and type LH for havinglow heat of hydration.

Similarly, the refining products of oil and gasses, or grades of otherminerals or chemicals produced within the high temperature environments,have distinctive corrosion and erosion effects on refractories. Thesespecific process requirements, aimed at achieving the required non-metalgrade, have a demonstrated effect on refractory lining performance.

Further, for purposes of the discussion herein, “alloying additions”could include “deoxidizers” to furnaces or other metallurgical vessels,such as, but not limited to, aluminum, silicon, ferro-silicon, calcium,magnesium, calcium carbide, and various deoxidizing blends, or additionsto ladle manufacturing vessels for secondary steelmaking and refining,such as, but not limited to, carbon, manganese, vanadium, molybdenum,chromium, nickel, titanium, boron, niobium, and other similar materialsknown to those having ordinary skill in the art.

The process of alloying steel is used to change the chemical compositionof steel and alter, adjust, or improve its properties to suit aspecification or application. The purpose of deoxidizers is to lower theconcentration of oxygen in liquid steels. The additions are added byweight during the melting processes and refining processes, and theydiffer based on the starting and target parameters of each individualheat. The quantity and quality of these alloying additions havesignificant effect not only on the quality of the steel, but also on thecorrosion of refractory linings.

Still moreover, for purposes of the discussion herein, “slag” withrespect to the process for the production or refining of molten steelcould include solutions of molten metal oxides and fluorides floating onthe top of liquid steel, and could be formed by materials such as, butnot limited to, lime, dolomitic lime, and magnesia, which are addedprior or during the steel-making and refining processes and are thebasis for the creation of slags. Additionally, for purposes of thediscussion herein, “flux additions” are added to optimize the fluidityof operating slags, and may include calcium aluminate, fluorspar, silicasand, or various blends of synthetic slags.

“Slags” with respect to the process for the production or refining ofmolten steel are primarily liquid at the temperatures at which steelmaking and steel refining take place. They play a role in the steelmaking process, absorbing non-metallic compounds from thedecarburization, deoxidation, desulfurization, and dephosphorizationprocesses. The additions of slag former and fluxes could vary from heatto heat and can be as low as few pounds per ton of steel and as high asseveral hundred pounds per ton of steel. The quantity and the quality ofthese additions have a direct influence on the chemical composition ofliquid slag and on the corrosion of refractory linings.

The typical chemical composition of the “slags” during the refiningprocesses of molten steel is identified in Table 1. An out-of-balanceslag chemical composition has a significant negative impact on the lifeof a refractory lining. The chemical compositions of a processed coldsample can be measured by, for example, an XRF unit, thereby employingan x-ray fluorescence analytical technique to determine the chemicalcomposition. While not discussed in detail below, a unit that canmeasure the chemical composition of a processed cold sample will bereferred to as slag chemistry measurement apparatus 3.

TABLE 1 Ideal Vessel Slag Composition Ideal Vessel Slag CompositionSilicon Aluminum Component Killed Killed CaO 50-60% 50-60% SiO₂ 25-30%  <8% MgO  7-10%  7-10% Al₂O₃   <8% 25-30% FeO + MnO   <2%   <2%

Additionally, for purposes of the discussion herein, “coatings” withrespect to the high temperature process for the production or refiningof glass, cement, lime, chemicals, oils and gasses, or other materialstypically called as non-metals could include solutions, or blends ofnon-metal oxides and fluorides generated in certain conditions duringthe operational cycle and in certain locations of the manufacturingvessel. The “coatings” adhere to the refractory surface at thetemperatures at which non-metal making or refining take place. Theycould have a direct influence on the corrosion of refractory linings.

The temperature of steel is defined as such prior to tapping (orremoval) of the steel from the primary melter, i.e., the furnace vessel,in the range between 2800° F. and 3200° F., or during or near the end ofsecondary steelmaking in a ladle vessel in the range between 2700° F.and 3000° F. Temperature is usually measured by thermoelectricthermocouples with effectiveness within several degrees ° F., such asladle thermocouple 25, which are dipped in the molten metal or moltensteel and preferably expendable. The application of ladle thermocouple25 in predictive refractory performance measurement system 4, as well assystem 4 itself, will be described in further detail in the followingdiscussion.

The temperature of a manufacturing vessel or the operational cycle withrespect to the high temperature process for the production or refiningof glass, cement, lime, chemicals, oils and gasses, or other materialstypically called as non-metals is between 2000° F. to 3400° F. for glassmelters, between 1600° F. to 2700° F. for cement kilns, between 600° F.to 1600° F. for preheat towers, up to 2200° F. for coolers, between1200° F. to 1400° F. for fluid catalytic cracking units, between 2400°F. to 2800° F. for thermal reactors, up to 2200° F. for ammoniareformers, up to 3000° F. for incinerators, between 2400° F. to 3000° F.for gasifiers, and between 1500° F. to 2200° F. for fluidized beds.Again, temperature is usually measured by thermoelectric thermocoupleswith effectiveness within several degrees ° F.

Additionally, for purposes of this discussion, a “history” of ametallurgical vessel refers to a period in which the same refractorylining has been lined over the inner surface of the outer wall of themetallurgical vessel. The history is typically recorded through thecollection of various “ladle tracking parameters”, which include, butare not limited to, heats, plate changes, nozzle changes, and otherevents that affect metallurgical vessels during the steel-making processin such a way that would affect the life span of refractory liningsinstalled therein. More specifically, the ladle tracking parametersidentify when the refractory lining of metallurgical vessel is subjectedto repair, change, or demolition.

For example, newly installed working refractory lining of ametallurgical vessel, such as working refractory lining 34, has zeroheats and has initial chemical compositions, origins, and physicaldesigns. After service exposure, some of the components of themetallurgical vessel may require change or repair. Examples of suchchanges could be, but are not limited to a replacement of the flowcontrol slide gate (after as low as 1 heat and as high as 15 heats), areplacement of flow control upper or lower nozzles (after as low as fewheat up to 30 heats or higher), a replacement of a gas purging cone, areplacement of a well block and pocket blocks (as low as 15 heats and ashigh as life of the ladle), and a replacement of the slag line (as lowas 15 heats and as high as the life of the unit).

Additionally, for purposes of this discussion, a “history” of amanufacturing vessel with respect to the high temperature process forthe production or refining of glass, cement, lime, chemicals, oils andgasses, or other materials typically called as non-metals refers to aperiod in which the same refractory lining has been lined over the innersurface of the outer wall of the manufacturing vessel. The history istypically recorded through the collection of various “process trackingparameters”, which include, but are not limited to, number ofoperational cycles, number of inspections, number of preventive or acutemaintenance stoppages, and other events that affect manufacturingvessels during the non-metal-making process in such a way that wouldaffect the life span of refractory linings installed therein. Morespecifically, the manufacturing vessel tracking parameters identify whenthe refractory lining of manufacturing vessel is subjected to repair,change, or demolition.

There are additional repairs possible with respect to the metallurgicalvessel, such as, but not limited to, a monolithic patch of a bottom of aladle vessel and a repair of the ladle vessel lip ring. The ladle vesselat a final demolition thereof could have exposed working refractorylining 34 to as low as a few heats and as high as greater than 200heats. Variable ladle tracking parameters have significant effects onthe overall performance of the refractory lining. The repairs or changesto the metallurgical vessel typically require the vessel to be taken outof service, thereby resulting in thermal shock or thermal gradientdamage to the refractory lining positioned therein.

There are also additional repairs possible with respect to themanufacturing vessel used for the high temperature process for theproduction or refining of glass, cement, lime, chemicals, oils andgasses, or other materials typically called as non-metals. These repairsor changes to the manufacturing vessel typically require the vessel tobe taken out of service, thereby resulting in thermal shock or thermalgradient damage to the refractory lining positioned therein.

Still additionally, for purposes of this discussion, “preheating” or“heat up” refers to exposing a metallurgical or a manufacturing vesselto a gas-powered preheater prior to exposure to molten metal or steelwith respect to the metallurgical vessel or an operational cycle withrespect to the manufacturing vessel. Specifically, with respect to ametallurgical vessel, each empty metallurgical vessel, if in operation,should be kept hot. The preheating or heat up in both metallurgical andmanufacturing vessels influences the performance of refractory linings.An example of the preheating that is used in the process for theproduction or refining of molten steel is working refractory lining 34.

The preheating temperature may be measured by thermocouples. Examples ofthis method of temperature measurement used in the process for theproduction or refining of molten steel include preheater thermocouple 2,which is described in further detail below, or optical pyrometers. Thepreheating temperatures in the process for the production or refining ofmolten steel are typically in a range of 1500° F. to 2200° F. However,since working refractory linings used in the process for the productionor refining of molten steel, such as working refractory lining 34,usually contain graphite and carbon, any non-typical preheating exposurehas direct impact on the carbon depletion and consequently on theperformance of working refractory lining 34. While necessary, thepreheating of working refractory linings used in the process for theproduction or refining of molten steel, such as working refractorylining 34, predictably shortens the refractory life of the workingrefractory linings, which impacts the future status of the workingrefractory linings.

Further, the duration of the preheating or heat up of the metallurgicalor manufacturing vessel is not predetermined. Instead, the duration isdependent upon the variables and circumstances defined in the area, orshop, in which the process takes place. Such variables and circumstancesmay include, but are not limited to, operational inconsistencies,process backlogs, availability of molten metal in the case of themetallurgical vessel, availability of charging or continuously fed mixingredients or fuels in the case of the manufacturing vessel, unforeseenrepairs, or emergency maintenance shutdowns of process equipment. Assuch, the duration of the preheating or heat up must be monitored by arecording mechanism, such as preheating or heat up recording apparatus24, which is described in greater detail below.

Moreover, for the purposes of this discussion, “residence time” withrespect to the process for the production or refining of molten steel isdefined as the cumulative contact time of working refractory lining 34with molten steel and slags. The residence time is not predetermined andhighly depends on the variables and circumstances defined in the area,or shop, in which the process takes place. For example, the process flowof the steel mill can affect the cumulative contact time of workingrefractory lining 34 with molten steel and slags from as low as 30minutes to as high as 10 hours or more per each heat. As such, thecumulative contact time must be monitored by a recording mechanism, suchas residence time recording apparatus 23, which is described in greaterdetail below.

Additionally, for the purposes of this discussion, “cycle time” withrespect to the high temperature process for the production or refiningof glass, cement, lime, chemicals, oils and gasses, or other materialstypically called as non-metals is defined as the cumulative contact timeof refractory lining with high temperature corrosion and erosionenvironments. The cycle time is not predetermined and highly depends onthe variables and circumstances defined in the area, or shop, in whichthe process takes place. For example, the process flow in non-metal millcan affect the cumulative contact time of refractory lining and as such,the cumulative contact time must be monitored by a recording mechanism,such as cycle time recording apparatus 423, which is described ingreater detail below.

Further, specifically with respect to the process for the production orrefining of molten steel, metallurgical vessels are typically equippedwith stirring elements located in the bottom thereof. They purge inertgas, such as argon or nitrogen, thru molten steel. The main purpose ofthis is to improve and accelerate desulfurization of the molten steel,but also to improve alloying efficiency and temperature homogenizationof the molten steel. The stirring pressure is typically in the range of120 psi to 180 psi, and the gas volume is typically between 5-50 scfm.The normal flow volumes are typically 5-10 scfm for a gentle stir andrinse, 15-25 scfm for a medium stir during arcing, alloy addition, andhomogenization, and 25-45 scfm for heavy desulfurization. Flows vary byvessel size, plug location, and plug conditions. The purging durationduring the heat could be in the range of a few minutes to 30 minutes ormore. The typical life of the purging plug is between 500 minutes and2,000 minutes. The stirring pressure, flow, and time influence not onlythe life of the plug, but localized erosion of working refractory lining34. Thus, as is the case with the preheating and the residence time, theparameters related to the stirring of the molten steel are notpredetermined, but are dependent on the efficiency of thedesulfurization of the steel. For example, the level of sulfur ismeasured prior to the tapping of the molten steel. If the target ofdesulfurization is not reached, additional stirring time, increasedstirring pressure, and higher flowrate is applied. Increases andelevations in these parameters are known to result in a reduced lifespan of working refractory lining 34. These parameters can be monitoredand recorded in gas stirring control apparatus 26, which will bediscussed further below.

In addition, for purposes of this discussion, with respect to theprocess for the production or refining of molten steel, a physicalorientation of a metallurgical vehicle corresponds with the position ofthe metallurgical vehicle in relationship to an overall space of thearea in which the metallurgical vehicle is being used, such as a steelmill or any other facility dedicated to steel generation.

Referring now to the drawings, wherein the showing is for illustrating apreferred embodiment of the invention only and not for limiting same,the invention with respect to the process for the production or refiningof molten steel will be described with reference to FIGS. 1-3.

FIG. 1 is a schematic view illustrating an example of predictiverefractory performance measurement system 4. System 4 is used to predictthe future status, or performance, of refractory linings that are linedover inner surfaces of outer walls of metallurgical vessels for handlingmolten metal or molten steel. Predictive refractory performancemeasurement system 4 may be implemented in a mill, foundry, or otherenvironments known by those of ordinary skill in the art to be suitablefor the melting, forming, and refining of steel and metal. However, itis contemplated that a substantial portion of system 4 could beimplemented in any environment in which surface analysis, temperatureanalysis, process data analysis, and life expectancy calculation aredesired for refractories.

The example apparatuses, units, modules, devices, and other componentsillustrated in FIG. 1 that make up system 4 and perform the method andoperations described herein with respect to FIGS. 2 and 3 areimplemented by hardware components. Examples of hardware components arenot limited to the above-described example apparatuses, units, modules,and devices and may include controllers, sensors, generators, drivers,and any other electronic components known to one of ordinary skill inthe art. Such components may be variably located according to designneeds and may communicate with each other through wired or wirelessmeans.

In the non-limiting example described herein, system 4 includescomputing complex 10. Computing complex 10 may include one or moreprocessors 12 and one or more means of storage 14, but is not limitedthereto. Processors 12 and storage 14 of computing complex 10 may beoriented, positioned, or connected in any way to facilitate properoperation of computing complex 10. This includes, but is not limited to,wired configurations, wireless configurations, local configurations,wide area configurations, and any combination thereof in whichcommunication therebetween can be established through compatible networkprotocol.

Processor 12 is implemented by one or more processing elements. Suchprocessing elements may be as an array of logic gates, a controller andan arithmetic logic unit, a digital signal processor, a microcomputer, aprogrammable logic controller, a field-programmable gate array, aprogrammable logic array, a microprocessor, or any other device orcombination of devices known to one of ordinary skill in the art that iscapable of responding to and executing instructions in a defined mannerto achieve a desired result.

For simplicity, the singular term “processor” may be used in thedescription of the example processor 12 described herein, but in otherexamples multiple processors 12 are used, or processor 12 includesmultiple processing elements, or multiple types of processing elements,or both. In one example, system 4 of hardware components includesmultiple processors 12 in computing complex 10, and in another example,a hardware component of system 4 includes an independent processor oranother controller containing a processor, which then communicates datato receive data from processor 12 of computing complex 10. Processor 12of computing complex 10 may be defined as a hardware component, alongwith other components of system 4 discussed below. Similar to processor12 and other hardware components containing processing functionality maybe defined according to any one or more of different processingconfigurations, examples of which include a single processor,independent processors, parallel processors, single-instructionsingle-data (SISD) multiprocessing, single-instruction multiple-data(SIMD) multiprocessing, multiple-instruction single-data (MISD)multiprocessing, and multiple-instruction multiple-data (MIMD)multiprocessing. Processor 12 may be connected via cable or wirelessnetwork to hardware components to provide instruction thereto or toother processors to enable multiprocessing capabilities.

Instructions or software to control processor 12 or hardware includingprocessors within system 4 to implement the hardware components andperform the methods as described below are written as computer programs,code segments, instructions or any combination thereof, for individuallyor collectively instructing or configuring processor 12 or hardwareincluding processors within system 4 to operate as a machine orspecial-purpose computer to perform the operations performed by thehardware components and the methods as described below. In one example,the instructions or software include machine code that is directlyexecuted by processor 12 or hardware including processors within system4, such as machine code produced by a compiler. In another example, theinstructions or software include higher-level code that is executed byprocessor 12 or hardware including processors within system 4 using aninterpreter.

Programmers of ordinary skill in the art can readily write theinstructions or software based on the flow chart illustrated in FIG. 3and the corresponding descriptions herein, which disclose algorithms forperforming the operations performed by the hardware components and themethods as described above.

Hardware components implemented in system 4, such as processor 12 orcomponents linked to processor 12, execute instructions or software,such as an operating system (OS) and one or more software applicationsthat run on the OS, to perform the operations described herebelow withrespect to FIGS. 2 and 3.

The instructions or software to control processor 12 or hardwareincluding processors within system 4 to implement the hardwarecomponents and perform the methods as described below, and anyassociated data, data files, and data structures, are recorded, stored,or fixed in storage 14. Storage 14 of computing complex 10 genericallyrefers to one or more memories storing instructions or software that areexecuted by processor 12. However, the hardware components implementedin system 4, such as processor 12 or components linked to processor 12,may include local storage or access, manipulate, process, create, andstore data in storage 14 in response to execution of the instructions orsoftware.

Storage 14 may be represented by on one or more non-transitorycomputer-readable storage media. Storage 14 may be representative ofmultiple non-transitory computer-readable storage media linked togethervia a network of computing complex 10. For example, non-transitorycomputer-readable storage media may be located in one or more storagefacilities or one or more data centers positioned remotely from system 4within computing complex 10. Such a media may be connected to system 4through a network of computing complex 10. The network of computingcomplex 10 allows the non-transitory computer-readable storage mediaremotely located at the data center or the storage facility to transferdata over the network to non-transitory computer-readable storage mediumwithin storage 14 of computing complex 10. In addition, storage 14 maybe representative of both remotely and locally positioned non-transitorycomputer-readable storage media.

Examples of a non-transitory computer-readable storage medium includeread-only memory (ROM), random-access memory (RAM), flash memory, solidstate memory, CD-ROMs, CD-Rs, CD+Rs, CD-RWs, CD+RWs, DVD-ROMs, DVD-Rs,DVD+Rs, DVD-RWs, DVD+RWs, DVD-RAMs, BD-ROMs, BD-Rs, BD-R LTHs, BD-REs,magnetic tapes, floppy disks, magneto-optical data storage devices,optical data storage devices, hard disks, solid-state disks, and anydevice known to one of ordinary skill in the art that is capable ofstoring the instructions or software and any associated data, datafiles, and data structures in a non-transitory manner and providing theinstructions or software and any associated data, data files, and datastructures to processor 12 of computing complex 10 or hardware includingprocessors within system 4 so that processor 12 or processors canexecute the instructions. In one example, the instructions or softwareand any associated data, data files, and data structures are distributedover network-coupled computer systems so that the instructions andsoftware and any associated data, data files, and data structures arestored, accessed, and executed in a distributed fashion by processor 12.

Examples of hardware components in system 4 other than processor 12 andstorage 14 of computing complex 10 may include terminal 6. Terminal 6may include a user input, a display, or a combination thereof, but isnot limited thereto. In FIG. 1, terminal 6 is illustrated as beingconnected to computing complex 10. However, embodiments disclosed hereinare not limited thereto. For example, terminal 6 may be connecteddirectly to processor 12, directly to storage 14, to both storage 14 andprocessor 12, or to any other hardware component of system 4.

Terminal 6 may be configured to display information contained in storage14 that has been processed by processor 12 or inputted by a user.Processor 12 is in charge of determining what should be displayed onterminal 6. Storage 14 may be configured to store data generated byprocessor 12 and inputted through terminal 6. Applications, user input,and processor calculations may be stored in storage 14 for access byprocessor 12 in order to predict refractory performance.

Further examples of the above-referenced hardware in system 4 connectedto storage 14 may also include slag chemistry measurement apparatus 3,laser scanner 20, preheater thermocouple 2, infrared cameras 22,residence time recording apparatus 23, preheating recording apparatus24, gas stirring control apparatus 26, ladle thermocouple 25, andorientation laser 19. Storage 14 may receive data from these hardwarecomponents in any wired or wireless manner known to those havingordinary skill in the art and communicate the received and stored datato processor 12 in any wired or wireless manner known to those havingordinary skill in the art for further processing. These operationalcomponents will be more particularly described in the discussion below.

FIG. 2 is a schematic view illustrating an example refractory liningbeing lined over an inner surface of an outer wall of ladle vessels 16and 18 for which a future status of the refractory lining is to bepredicted by predictive refractory performance measurement system 4.Ladle vessel 16 does not contain molten metal or molten steel and,therefore, is referred to as “empty ladle vessel 16”. Ladle vessel 18contains molten metal or molten steel and, therefore, is referred to as“full ladle vessel 18”. Ladle vessels 16 and 18 of FIG. 2 arerepresentative of secondary refining and transport vessels, such assteel ladles.

Each of ladle vessels 16 and 18 are lined with the same refractory. Inthe examples illustrated in FIG. 2, backup refractory lining 32 is linedover an inner surface of an outer wall of ladle vessels 16 and 18.Working refractory lining 34 is lined over backup refractory lining 32.

Since working refractory lining 34 is lined over backup refractorylining 32, backup refractory lining 32 typically has a relatively longlife span. For example, backup refractory lining 32 may be able to havea one-year lifespan. On the other hand, during steel-making heats,working refractory lining 34 is directly exposed to the molten metal ormolten steel placed within ladle vessels 16 and 18. Thus, workingrefractory lining 34 typically has a much shorter life span. Dependingon the severity of the steel-making processes employed during the heats,working refractory lining 34 may only last for 2 weeks. As such, whileworking refractory lining 34 of empty ladle vessel 16 is the same asworking refractory lining 34 of full ladle vessel 18, it is assumedthat, during the heats, working refractory lining 34 of full ladlevessel 18 will be affected by the molten metal or molten steel containedtherein. Therefore, the structural condition of working refractorylining 34 in empty ladle vessel 16 prior to a heat being conducted maybe significantly different from the structural condition of workingrefractory lining 34 in empty ladle vessel 16 after each heat isconducted.

As previously noted, system 4 includes at least one laser scanner 20.Laser scanner 20 may be stationary or mobile. Laser scanner 20 isconfigured to scan working refractory lining 34 of empty ladle vessel 16before and after the heats of handling molten metal or molten steel.Laser scanner 20 may have a class 1 eye safe laser with the capabilityto scan with a frequency of 1,000,000 points in a second. Laser scanner20 may also have a scanning speed of 20 seconds and a 1 to 2 mmaccuracy.

Laser scanner 20 is supported by laser support apparatus 21. Lasersupport apparatus 21 may be a stationary support if laser scanner 20 isstationary or a mobile support if laser scanner 20 is mobile. If laserscanner 20 is mobile, laser support apparatus 21 may be any means ofsupport known by those of ordinary skill in the art to be suitable formoving mobile laser scanner 20. If laser scanner 20 is stationary, lasersupport apparatus 21 may be any means of fixable support known by thoseof ordinary skill in the art to be suitable for fixing stationary laserscanner 20.

The functions of scanning performed by laser scanner 20 include, but arenot limited to, collecting structural data related to observations ofpre- and post-heat structural conditions of working refractory lining 34in empty ladle vessel 16 respectively before and after heats in whichempty ladle vessel 16 is filled with molten metal or molten steel,thereby becoming full ladle vessel 18. This data is provided tocomputing complex 10 for safekeeping in storage 14 and/or considerationby processor 12 regarding the structural conditions of workingrefractory lining 34.

System 4 also may include one or more infrared cameras 22 that mayconduct one or more infrared scans of an outer surface of the outer wallof full ladle vessel 18 during the heat to collect data related to atemperature of the outer surface of the outer wall of full ladle vessel18 during the heat.

In one example, infrared cameras 22 may be placed in several locationswithin the process mill to strategically measure the temperature of theouter surface of the outer wall of full ladle vessel 18 as full ladlevessel 18 moves from a location in which full ladle vessel 18 is filledwith the molten steel to secondary steelmaking locations throughout theprocess mill, including locations in which refining takes place. Inanother example, infrared cameras 22 may be placed in a location withinthe process mill to strategically measure the temperature of the outersurface of the outer wall of empty ladle vessel 16 before and after theheats of handling molten metal or molten steel. Thermal discrepancies ofempty ladle vessel 16 can be identified even when empty ladle vessel 16is being preheated. The temperature data collected from infrared cameras22 can be mapped to identify deteriorating portions of workingrefractory lining 34 by processor 12.

Infrared cameras 22 may be any infrared camera known to those havingordinary skill in the art to be appropriate to image an outer surface ofan outer wall of a metallurgical vessel when charged with molten steel.The temperature data can be provided to computing complex 10 forsafekeeping in storage 14 and/or consideration by processor 12 regardingthe structural conditions of working refractory lining 34.

While an analysis utilizing ASTM 680-14 or heat transfer calculationsoftware developed for refractory design may be used to calculate thetemperature data of empty ladle vessel 16 or full ladle vessel 18obtained by infrared cameras 22 in view of thermal resistivity and heatfluxes, embodiments disclosed herein are not limited thereto. Forexample, any software or method of analysis known to one having ordinaryskill in the art to be able to calculate such temperature data can beutilized.

Further, the laser scanned data, the temperature data, or a combinationthereof communicated to computing complex 10 for consideration byprocessor 12 can be additionally considered alongside of other measuredand predetermined operational parameters stored in storage 14 that areawaiting communication to and consideration by processor 12. Themeasured operational parameters may be supplied to computer complex 10for reference by processor 12 through previously discussed hardwaremeans, including, but not limited to, slag chemistry measurementapparatus 3, preheater thermocouple 2, residence time recordingapparatus 23, preheating recording apparatus 24, gas stirring controlapparatus 26, and ladle thermocouple 25. The predetermined operationalparameters may be supplied to computer complex 10 through terminal 6 viauser input or historical data previously processed by processor 12 andstored in storage 14 for future reference regarding the future statusprediction for working refractory lining 34.

Predetermined operational parameters may include, but are not limitedto, historical data related to one or more refractories applied in oneor more historical refractory linings lined over inner surfaces of outerwalls of historical metallurgical vessels that handled molten metal ormolten steel, an initial chemical composition and origin of workingrefractory lining 34, an initial physical design of working refractorylining 34, a grade of the steel that is desired to be produced duringthe heat from the molten steel in the metallurgical vessel, physical andchemical attributes and amounts of charging mix components added to themetallurgical vessel during the heat to produce the desired steel gradefrom the molten steel, physical and chemical attributes and amounts ofalloys added to the metallurgical vessel during the heat for secondarysteelmaking and refining, physical and chemical attributes and amountsof slag formers added to the molten steel in the metallurgical vesselduring the heat to form slags that absorb non-metallic components fromthe molten steel to produce the desired steel grade from the moltensteel, physical and chemical attributes and amounts of flux additivesadded to the molten steel in the metallurgical vessel to optimizefluidity of the formed slags to produce the desired steel grade from themolten steel, a history of the metallurgical vessel during a period inwhich working refractory lining 34 has been lined over the liner surfaceof the outer wall of the metallurgical vessel, or any other relevantpredetermined operational parameter identified in a specific metalproducing operation.

For purposes of this application, the physical design of workingrefractory lining 34 may include, but is not limited to, constructiondetails of working refractory lining 34, shapes of refractory componentsin working refractory lining 34, sizes of refractory components inworking refractory lining 34, and combination of refractory componentsin working refractory lining 34.

Measured operational parameters may include, but are not limited to, apreheating duration during which the metallurgical vessel is empty andbeing preheated prior to the heat, a residence time defined by thecumulative contact duration during which the molten steel, the slags, ora combination thereof are in contact with working refractory lining 34during the process to produce the molten steel, an amount of stirringpressure applied by a stirring of the molten steel in the metallurgicalvessel, a flow rate of inert gas applied to the molten steel in themetallurgical vessel during the stirring of the molten steel in themetallurgical vessel, a stirring duration during which the molten metalis stirred, or any other relevant measured operational parameteridentified in a specific metal producing operation.

Using the above-referenced data, processor 12 may determine an exposureimpact that the heat has had on working refractory lining 34 of themetallurgical vessel and predict a future status of working refractorylining 34 after one or more subsequent heats. The exposure impact thatthe heat has on working refractory lining 34 may be determined bycomparing the structural conditions of working refractory lining 34before the heat with the structural conditions of working refractorylining 34 after the heat. The future status of working refractory lining34 after one or more subsequent heats is predicted based on thedetermined exposure impact. In other words, the exposure impact of theinitial heat can be used to predict the future status of workingrefractory lining 34 after a second heat, a third heat, and so on.Processor 12 may consider data from all data sources referenced above,but is not limited to thereto and could conceivably include other datasources not mentioned herein.

In one example, in order to supplement the prediction of the futurestatus of working refractory lining 34, the determination of theexposure impact of working refractory lining 34 may also be supplementedby correlating the collected temperature data from infrared cameras 22with the structural conditions of working refractory lining 34 beforethe handling of the molten steel and the structural conditions ofworking refractory lining 34 after the handling of the molten steel.This may allow the future status to be more accurately predicted.

In another example, in order to supplement the prediction of the futurestatus of working refractory lining 34, the determination of theexposure impact of working refractory lining 34 may also be supplementedby considering, in correlation with the collected structural conditiondata, an operational impact that one or more of the aforementionedpredetermined or measured operational parameters have on the exposureimpact of the heat on working refractory lining 34.

In one example, the historical data related to one or more refractoriesapplied in one or more historical refractory linings lined over innersurfaces of outer walls of historical metallurgical vessels that handledmolten metal or molten steel may be used to establish historicalpatterns of exposure impact. Such historical patterns may complement thecomparison of the structural conditions of working refractory lining 34before the handling of the molten metal or molten steel with thestructural conditions of working refractory lining 34 after the handlingof the molten metal or molten steel, as well as the correlation of thecollected temperature data from infrared cameras 22 therewith. Suchhistorical data could be amassed in storage 14 of computer complex 10after exposure impact determination to enable processor 12 to predictthe future status of subsequent working refractory linings after eachsuccessive heat with more accuracy.

With respect to the use of the measured operational parameters to assistin determination of the exposure impact, ladle thermocouple 25 can beprovided to measure a temperature of the molten metal or molten steel infull ladle vessel 18. In one example, ladle thermocouple 25 may beinserted through aperture 40 of full ladle vessel 18 and into moltensteel to measure the temperature of the molten steel during or at theend of the secondary steelmaking process (e.g., the end of the refiningprocess). Ladle thermocouple 25 may provide the measured temperaturedata to computing complex 10 for considering by processor 12 during thedetermination of the exposure impact pursuant to the prediction of thefuture status of working refractory lining 34.

In addition, slag chemistry measurement apparatus 3 may be provided tomeasure a chemical composition of a slag generated in a metallurgicalvessel during the secondary steelmaking process. As previously noted,for measurement of the chemical composition, a sample of the slag mustbe cooled. Slag chemistry measurement apparatus 3 may be, for example,an XRF unit, thereby employing an x-ray fluorescence analyticaltechnique to determine the chemical composition. Slag chemistrymeasurement apparatus 3 may provide the measured chemical composition ofa slag to computing complex 10 for consideration by processor 12 duringthe determination of the exposure impact pursuant to the prediction ofthe future status of working refractory lining 34.

Moreover, preheater thermocouple 2 may be provided to measure atemperature of the metallurgical vessel when the metallurgical vessel isempty and being preheated prior to the metallurgical vessel being filledof the molten metal or molten steel. Preheater thermocouple 2 mayprovide the measured preheater temperature to computing complex 10 forconsideration by processor 12 during the determination of the exposureimpact pursuant to the prediction of the future status of workingrefractory lining 34.

To monitor the residence time duration, a recording mechanism, such asresidence time recording apparatus 23 featured herein, may be used tomeasure the cumulative contact duration during which the molten metal,slags, or a combination thereof are in contact with the refractorylining during a heat.

In addition, to monitor the duration of the preheating, a recordingmechanism, such as preheating recording apparatus 24 featured herein,may be used to record the duration of the preheating performed on anempty metallurgical vessel prior to a heat. Specifically, the durationof the preheating could be measured by preheating recording apparatus 24as being as little as a few minutes and as great as several days.Preheating recording apparatus 24 may be included in a gas-poweredpreheater, along with an automatic gas shut-off.

Further, a control mechanism, such as gas stirring control apparatus 26,may be used to measure various stirring parameters, including, but notlimited to, an amount of stirring pressure applied by a stirring of themolten steel in a full metallurgical vessel, a flow rate of inert gasapplied to the molten steel in the full metallurgical vessel during thestirring of the molten steel in the full metallurgical vessel, and astirring duration during which the molten metal is stirred.

Orientation laser 19 can be provided to scan the empty ladle vessel 16to identify a physical orientation of the empty ladle vessel 16 prior tothe laser scanning of working refractory lining 34 by laser scanner 20.The scanning performed by orientation laser 19 serves to assist andincrease the accuracy of the laser scanning of working refractory lining34 performed by laser scanner 20. The physical orientation of the emptyladle vessel 16 relates to the position of empty ladle vessel 16 withrespect to the process or facility in which empty ladle vessel 16 isbeing used. Orientation laser 19 provides the identified physicalorientation of the metallurgical vessel to computing complex 10 forconsideration by processor 12 to determine correct positioning of emptyladle vessel 16 for accurate determination of the exposure impactpursuant to the prediction of the future status of working refractorylining 34.

More particularly, data from orientation laser 19 may allow processor 12to determine thickness measurements from spatial measurements of thesurface of working refractory lining 34. Such measurements cannot bederived unless the physical location and orientation of empty ladlevessel 16 is assumed or precisely known. Data from orientation laser 19may allow processor 12 to precisely know the physical location andorientation of empty ladle vessel 16.

While orientation laser 19 is shown in FIG. 2 to be positioned directlyunder empty ladle vessel 16, embodiments disclosed herein are notlimited thereto. For example, orientation laser 19 can be positioned inany safe and unobstructed placed with a direct visibility of the outerwall of empty ladle vessel 16, so that orientation laser 19 might bepositioned to scan the bottom and the lower portion of empty ladlevessel 16. It is also noted that physical orientation identification byorientation laser 19 can be supplemented through the data provided bylaser scanner 20 regarding empty ladle vessel 16.

Referring now to FIGS. 2 and 3, method 100 of predicting a future statusof working refractory lining 34 that is lined over an inner surface ofan outer wall of a metallurgical vessel and exposed to a heat duringwhich the refractory lining is exposed to molten metal or molten steelis described.

For purposes of discussion of method 100, “metallurgical vessel” mayrefer to a ladle vessel that is exposed to molten metal or molten steel.A ladle vessel in method 100 refers generally to empty ladle vessel 16and full ladle vessel 18 in situations in which the emptiness or thefullness of the ladle vessel is not at issue. In addition, in oneexample, empty ladle vessel 16 receives molten steel from a furnace whenmolten steel is tapped therefrom. As such, empty ladle vessel 16transitions to full ladle vessel 18 when molten steel is tapped from thefurnace into empty ladle vessel 16.

Moreover, while method 100 is not limited to processes in which ametallurgical vessel is transported, it is assumed that, during a heatin method 100, ladle vessels 16 and 18 are transported throughout theprocess location or mill through transport means known to those havingordinary skill in the art, such as, but not limited to, cranes,conveyors, rails, and bearings. Further, computing complex 10, includingprocessor 12 and any other control unit contained therein, is enabled tocontrol all processes, including, but not limited to, scanning,measuring, transporting, transferring of metals, observing, collecting,determining, predicting, and considering.

A schematic illustration of the transportation of ladle vessel 16 and 18is illustrated in FIG. 2. Empty ladle vessel 16 and full ladle vessel 18are illustrated separately. In an example, empty ladle vessel 16 may beinitially scanned to identify a physical orientation of empty ladlevessel 16 prior to any scanning of working refractory lining 34. Such aninitial scan may be performed by orientation laser 19, which wasdiscussed above. The physical orientation of empty ladle vessel 16 maybe taken into account by processor 12 during any further considerations,determinations, and predictions by processor 12 with respect to ladlevessels 16 or 18.

In addition, after physical orientation scanning and prior to anyscanning of working refractory lining 34, while empty ladle vessel 16 isbeing preheated in preparation for a heat, a preheating temperature anda preheating duration during which empty ladle vessel 16 is beingpreheated prior to the heat may be recorded. The preheating temperaturemay be measured by preheater thermocouple 2, and the preheating durationmay be recorded by preheating recording apparatus 24. The preheatingtemperature and the preheating duration may be used by processor 12 asmeasured parameters in considering an operational impact that theoperational parameters related to the steelmaking have on the structuralconditions of working refractory lining 34 after the handling of themolten metal or molten steel.

Further measurement of operational parameters, such as, but not limitedto, a measurement of temperature of the molten metal or molten steel infull ladle vessel 18 by ladle thermocouple 25, a measurement of achemical composition of a slag in full ladle vessel 18 by slag chemistrymeasurement apparatus 3, a measurement of the cumulative contactduration during which the molten steel, the slags, or a combinationthereof are in contact with working refractory lining 34 during the heatby residence time recording apparatus 23, and a measurement of a varietyof stirring parameters by gas stirring control apparatus 26, may beperformed during a heat and will be described in detail below.Predetermined operational parameters, as described above, may beprovided to computing complex 10 when convenient. However, as haspreviously been noted and will be described further below, anypredetermined operational parameters provided to computing complex 10will be considered by processor 12 in the determination of the exposureimpact on working refractory lining 34.

After any additional preparative steps are completed, prior to a heat, alaser scan of working refractory lining 34 of empty ladle vessel 16 isconducted (S101). The conducting of the laser scan prior to the heat maybe performed by laser scanner 20. The conducting of the laser scan priorto the heat may also include the collecting of data related to pre-heatstructural conditions of working refractory lining 34.

Then, a heat is performed, during which empty ladle vessel 16 is filledwith molten metal or molten steel, thus becoming full ladle vessel 18.This is illustrated in the flow of FIG. 2, where empty ladle vessel 16is illustrated at one portion of the process and full ladle vessel 18 isillustrated at a later point in the process. During the heat, full ladlevessel 18 is emptied and becomes empty ladle vessel 16, as isillustrated by the flow in FIG. 2.

After the heat is completed, another laser scan of working refractorylining 34 of empty ladle vessel 16 is conducted (S102). Similar to theconducting of the laser scan prior to the heat, the conducting of thelaser scan after the heat may be performed by laser scanner 20. Further,the conducting of the laser scan after the heat may also include thecollecting of data related to post-heat structural conditions of workingrefractory lining 34.

After the laser scanning prior to the heat and the laser scanning afterthe heat, processor 12 determines (S103) an exposure impact of the heaton working refractory lining 34. Processor 12 may determine the exposureimpact by comparing the collected pre-heat structural condition datawith the collected post-heat structural condition data. After thedetermination of the exposure impact of the heat, processor 12 predicts(S104) the future status of working refractory lining 34 after one ormore subsequent heats based on the determination of the exposure impactof the heat.

This prediction provides information that is crucial to determinewhether the ladle vessel can be used again with working refractorylining 34 or if working refractory lining 34 needs replaced. As such,accidents that result in excessive structural damage to the ladle vesselcan be avoided, resulting in less down time, greater efficiency, andcost savings.

In one example, during the heat, one or more infrared scans of the outersurface of the outer wall of full ladle vessel 18 may be conducted byinfrared cameras 22. The scans enable infrared cameras 22 to collectdata related to the temperature of the outer surface detected during theheat. This temperature data may be correlated with the collectedstructural condition data to more accurately determine the exposureimpact and predict the future status.

In another example, the determining of the exposure impact includesconsidering, in correlation with the collected structural condition dataand, optionally, in this particular example, the collected temperaturedata from the infrared scanning, an operational impact that one or moreof the measured or predetermined operational parameters have on workingrefractory lining 34 during the heat.

The predetermined operational parameters include those predeterminedoperational parameters previously discussed herein, including, but notlimited to, historical data related to one or more refractories appliedin one or more historical refractory linings that handled molten metal,an initial chemical composition and origin of working refractory lining34, an initial design of working refractory lining 34, a grade of steelthat is desired to be produced during the heat, physical and chemicalattributes and amounts of charging mix components added to full ladlevessel 18 during the heat, physical and chemical attributes and amountsof alloys added to full ladle vessel 18 during the heat, physical andchemical attributes and amounts of slag formers added to full ladlevessel 18 during the heat, physical and chemical attributes and amountsof flux additives added to full ladle vessel 18 during the heat, and ahistory of ladle vessel 16 and 18 during a period in which workingrefractory lining 34 has been lined therein.

The measured operational parameters include those measured operationalparameters previously discussed herein, including, but not limited to, apreheating temperature during which empty ladle vessel 16 is beingpreheated prior to the heat measured by preheater thermocouple 2, apreheating duration during which empty ladle vessel 16 is beingpreheated prior to the heat measured by preheating recording apparatus24, a measurement of temperature of the molten metal or molten steel infull ladle vessel 18 by ladle thermocouple 25, a measurement of thecumulative contact duration during which the molten steel, the slags, ora combination thereof are in contact with working refractory lining 34during the heat by residence time recording apparatus 23, and ameasurement, by gas stirring control apparatus 26, of a variety ofstirring parameters, such as, but not limited to, an amount of stirringpressure applied by a stirring of the molten metal in full ladle vessel18 during the heat, a flow rate of inert gas applied to the molten metalin full ladle vessel 18 during the stirring, and a stirring durationduring which the molten metal is stirred.

Referring now to the drawings, wherein the showing is for illustrating apreferred embodiment of the invention only and not for limiting same,the invention with respect to the high temperature process for theproduction or refining of glass, cement, lime, chemicals, oils andgasses, or other materials typically called as non-metals will bedescribed with reference to FIGS. 4-6.

FIG. 4 is a schematic view illustrating another example of a predictiverefractory performance measurement system. Predictive refractoryperformance measurement system 404 is used to predict the future status,or performance, of refractory linings that are lined over inner surfacesof outer walls of manufacturing vessels for handling glass, cement,lime, chemicals, oils and gasses, or other materials typically referredto as non-metals. Predictive refractory performance measurement system404 may be implemented in a mill, shop, production area, or otherenvironments known by those of ordinary skill in the art to be suitablefor the melting, forming, sintering, densifying, converting and refiningof non-metal. However, it is contemplated that a substantial portion ofsystem 404 could be implemented in any environment in which surfaceanalysis, temperature analysis, process data analysis, and lifeexpectancy calculation are desired for refractories.

Systems 4 and 404 are similar, in that both systems 4 and 404 aredesigned to determine the condition of a refractory layer applied in anindustrial process after exposure during the industrial process tocorrosive material that could serve to cause the refractory layer todeteriorate. While much of the hardware in systems 4 and 404 isinterchangeable, certain types of hardware are unique to system 404. Inaddition, some hardware used in system 4 is not needed for the operationof system 404. Moreover, some of the corresponding hardware of systems 4and 404 may perform their functions uniquely, as the processes and manyof the measured components for which system 4 is used are different fromthose for which system 404 is used.

As is the case with system 4 and FIGS. 1-3, the example apparatuses,units, modules, devices, and other components illustrated in FIG. 4 thatmake up system 404 and perform the method and operations describedherein with respect to FIGS. 5 and 6 are implemented by hardwarecomponents. Examples of hardware components are not limited to theabove-described example apparatuses, units, modules, and devices and mayinclude controllers, sensors, generators, drivers, and any otherelectronic components known to one of ordinary skill in the art. Suchcomponents may be variably located according to design needs and maycommunicate with each other through wired or wireless means.

In the non-limiting example described herein, system 404 includescomputing complex 410. Computing complex 410 may include one or moreprocessors 412 and one or more means of storage 414, but is not limitedthereto. Processors 412 and storage 414 of computing complex 410 may beoriented, positioned, or connected in any way to facilitate properoperation of computing complex 410. This includes, but is not limitedto, wired configurations, wireless configurations, local configurations,wide area configurations, and any combination thereof in whichcommunication therebetween can be established through compatible networkprotocol.

Processor 412 is implemented by one or more processing elements. Suchprocessing elements may be as an array of logic gates, a controller andan arithmetic logic unit, a digital signal processor, a microcomputer, aprogrammable logic controller, a field-programmable gate array, aprogrammable logic array, a microprocessor, or any other device orcombination of devices known to one of ordinary skill in the art that iscapable of responding to and executing instructions in a defined mannerto achieve a desired result.

For simplicity, the singular term “processor” may be used in thedescription of the example processor 412 described herein, but in otherexamples multiple processors 412 are used, or processor 412 includesmultiple processing elements, or multiple types of processing elements,or both. In one example, system 404 of hardware components includesmultiple processors 412 in computing complex 410, and in anotherexample, a hardware component of system 404 includes an independentprocessor or another controller containing a processor, which thencommunicates data to receive data from processor 412 of computingcomplex 410. Processor 412 of computing complex 410 may be defined as ahardware component, along with other components of system 404 discussedbelow. Similar to processor 412 and other hardware components containingprocessing functionality may be defined according to any one or more ofdifferent processing configurations, examples of which include a singleprocessor, independent processors, parallel processors,single-instruction single-data (SISD) multiprocessing,single-instruction multiple-data (SIMD) multiprocessing,multiple-instruction single-data (MISD) multiprocessing, andmultiple-instruction multiple-data (MIMD) multiprocessing. Processor 412may be connected via cable or wireless network to hardware components toprovide instruction thereto or to other processors to enablemultiprocessing capabilities.

Instructions or software to control processor 412 or hardware includingprocessors within system 404 to implement the hardware components andperform the methods as described below are written as computer programs,code segments, instructions or any combination thereof, for individuallyor collectively instructing or configuring processor 412 or hardwareincluding processors within system 404 to operate as a machine orspecial-purpose computer to perform the operations performed by thehardware components and the methods as described below. In one example,the instructions or software include machine code that is directlyexecuted by processor 412 or hardware including processors within system404, such as machine code produced by a compiler. In another example,the instructions or software include higher-level code that is executedby processor 412 or hardware including processors within system 404using an interpreter.

Programmers of ordinary skill in the art can readily write theinstructions or software based on the flow chart illustrated in FIG. 6and the corresponding descriptions herein with respect to the hightemperature process for the production or refining of glass, cement,lime, chemicals, oils and gasses, or other materials typically called asnon-metals, which disclose algorithms for performing the operationsperformed by the hardware components and the methods as described above.

Hardware components implemented in system 404, such as processor 412 orcomponents linked to processor 412, execute instructions or software,such as an operating system (OS) and one or more software applicationsthat run on the OS, to perform the operations described here below withrespect to FIGS. 5 and 6.

The instructions or software to control processor 412 or hardwareincluding processors within system 404 to implement the hardwarecomponents and perform the methods as described below, and anyassociated data, data files, and data structures, are recorded, stored,or fixed in storage 414. Storage 414 of computing complex 410generically refers to one or more memories storing instructions orsoftware that are executed by processor 412. However, the hardwarecomponents implemented in system 404, such as processor 412 orcomponents linked to processor 412, may include local storage or access,manipulate, process, create, and store data in storage 414 in responseto execution of the instructions or software.

Storage 414 may be represented by on one or more non-transitorycomputer-readable storage media. Storage 414 may be representative ofmultiple non-transitory computer-readable storage media linked togethervia a network of computing complex 410. For example, non-transitorycomputer-readable storage media may be located in one or more storagefacilities or one or more data centers positioned remotely from system404 within computing complex 410. Such a media may be connected tosystem 404 through a network of computing complex 410. The network ofcomputing complex 410 allows the non-transitory computer-readablestorage media remotely located at the data center or the storagefacility to transfer data over the network to non-transitorycomputer-readable storage medium within storage 414 of computing complex410. In addition, storage 414 may be representative of both remotely andlocally positioned non-transitory computer-readable storage media.

Examples of a non-transitory computer-readable storage medium includeread-only memory (ROM), random-access memory (RAM), flash memory, solidstate memory, CD-ROMs, CD-Rs, CD+Rs, CD-RWs, CD+RWs, DVD-ROMs, DVD-Rs,DVD+Rs, DVD-RWs, DVD+RWs, DVD-RAMs, BD-ROMs, BD-Rs, BD-R LTHs, BD-REs,magnetic tapes, floppy disks, magneto-optical data storage devices,optical data storage devices, hard disks, solid-state disks, and anydevice known to one of ordinary skill in the art that is capable ofstoring the instructions or software and any associated data, datafiles, and data structures in a non-transitory manner and providing theinstructions or software and any associated data, data files, and datastructures to processor 412 of computing complex 410 or hardwareincluding processors within system 404 so that processor 412 orprocessors can execute the instructions. In one example, theinstructions or software and any associated data, data files, and datastructures are distributed over network-coupled computer systems so thatthe instructions and software and any associated data, data files, anddata structures are stored, accessed, and executed in a distributedfashion by processor 412.

Examples of hardware components in system 404 other than processor 412and storage 414 of computing complex 410 may include terminal 406.Terminal 406 may include a user input, a display, or a combinationthereof, but is not limited thereto. In FIG. 4, terminal 406 isillustrated as being connected to computing complex 410. However,embodiments disclosed herein are not limited thereto. For example,terminal 406 may be connected directly to processor 412, directly tostorage 414, to both storage 414 and processor 412, or to any otherhardware component of system 404.

Terminal 406 may be configured to display information contained instorage 414 that has been processed by processor 412 or inputted by auser. Processor 412 oversees determining what should be displayed onterminal 406. Storage 414 may be configured to store data generated byprocessor 412 and inputted through terminal 406. Applications, userinput, and processor calculations may be stored in storage 414 foraccess by processor 412 in order to predict refractory performance.

Further examples of the above-referenced hardware in system 404connected to storage 414 are illustrated in at least one of FIG. 4 or 5and may include, at least one laser scanner 420, auxiliary thermocouple402, one or more outer view infrared cameras 422, one or more inner viewinfrared cameras 403, cycle time recording apparatus 423, auxiliaryrecording apparatus 424, environment measuring thermocouple 425,non-metal measuring thermocouple 428, orientation laser 419, one or morepressure sensors 407, one or more gas sensors 409, and one or moretomography sensors 411 for radar/tomography scanning.

Some of this hardware may only be utilized in certain applications. Forexample, functional use of tomography sensors 411 for radar/tomographyscanning may be limited to applications for radar wave differentialmeasurements in which system 404 is being used to measure refractorylayers in glass melters.

Further, functional use of pressure sensors 407 and gas sensors 409 maybe limited to petrochemical applications in which system 404 is beingemployed to measure refractory lining 434 when manufacturing vessel 416includes burner systems, uses variable fuel feeds, or is under pressureand exposed to the presence of gases. Specifically, pressuremeasurements taken by pressure sensors 407 and gas-type measurementstaken by gas sensors 409 may be communicated to processor 412 forconsideration as to how exposure to the pressure and gas makeup withinmanufacturing vessel 416 impacts a life span of refractory lining 434.

Moreover, functional use of glass pull rate calculator via processor 412may be further configured to calculate a glass pull rate, whichrepresents the speed at which glass is melted in manufacturing vessel416 and is usually expressed in the number of tons of glass melted perday. Such calculations may be considered as to how the speed at whichthe glass is processed in manufacturing vessel 416, i.e., the amount ofmaterial passing through the manufacturing vessel 416 a day, impacts alife span of refractory lining 434.

Storage 414 may receive data from these hardware components in any wiredor wireless manner known to those having ordinary skill in the art andcommunicate the received and stored data to processor 412 in any wiredor wireless manner known to those having ordinary skill in the art forfurther processing. These operational components will be moreparticularly described in the discussion below.

FIG. 5 is a schematic view illustrating an example refractory lining 434being lined over an inner surface of an outer wall of manufacturingvessel 416 for which a future status of refractory lining 434 is to bepredicted by predictive refractory performance measurement system 404.In the examples illustrated in FIG. 5, refractory lining 434 is linedover an inner surface of an outer wall of manufacturing vessel 416.

Depending on the severity of the manufacturing processes employed duringthe operational cycles, refractory lining 434 may only last for a fewmonths. It is assumed that, during the operational cycles, refractorylining 434 of manufacturing vessel 416 will be affected by moltenliquids, or hot, abrasive, and erosive solids, or hot and corrosivegases. Therefore, the structural conditions of refractory lining 434 ofmanufacturing vessel 416 after each operational cycle may besignificantly different from the structural conditions of refractorylining 434 in manufacturing vessel 416 prior to each operational cycleconducted.

As previously noted, system 404 includes at least one laser scanner 420.Laser scanner 420 may be stationary or mobile. Laser scanner 420 isconfigured to scan refractory lining 434 before and after theoperational cycle of handling non-metals. Laser scanner 420 may have aclass 1 eye safe laser with the capability to scan with a frequency of1,000,000 points in a second. Laser scanner 420 may also have a scanningspeed of 20 seconds and a 1 to 2 mm accuracy.

Laser scanner 420 is supported by laser support apparatus 421. Lasersupport apparatus 421 may be a stationary support if laser scanner 420is stationary or a mobile support if laser scanner 420 is mobile. Iflaser scanner 420 is mobile, laser support apparatus 421 may be anymeans of support known by those of ordinary skill in the art to besuitable for moving mobile laser scanner 420. If laser scanner 420 isstationary, laser support apparatus 421 may be any means of fixablesupport known by those of ordinary skill in the art to be suitable forfixing stationary laser scanner 420.

The functions of scanning performed by laser scanner 420 include, butare not limited to, collecting structural data related to observationsof pre- and post-operational cycle structural conditions of refractorylining 434. This data is provided to computing complex 410 forsafekeeping in storage 414 and/or consideration by processor 412regarding the structural conditions of refractory lining 434.

System 404 also may include one or more outer view infrared cameras 422that may conduct one or more infrared scans of an outer surface of theouter wall of manufacturing vessel 416 during the operational cycle tocollect data related to a temperature of the outer surface of the outerwall of manufacturing vessel 416 during the operational cycle. System404 may further include inner view infrared cameras 403 to conduct oneor more infrared scans of an inner surface of the outer wall ofmanufacturing vessel 416 during the operational cycle to collect datarelated to a temperature of the inner surface of the outer wall ofmanufacturing vessel 416 during the operational cycle.

In one example, outer view infrared cameras 422 may be placed in severallocations around the outside wall of manufacturing vessel 416 tostrategically measure the temperature of the outer surface of the outerwall of manufacturing vessel 416. The thermal reading during theoperational cycle and between the operational cycles can be recorded byouter view infrared cameras 422 and analyzed for thermal discrepancies.The temperature data collected from outer view infrared cameras 422 canbe then mapped to identify deteriorating portions of refractory lining434 by processor 412.

In another example, inner view infrared cameras 403 may be placed inlocations which would allow for measurement of temperatures of the innersurface of the outer wall of manufacturing vessel 416. Such locationsmay include, but are not limited to, entry opening 440 of manufacturingvessel 416, exit opening 418 of manufacturing vessel 416, or any otheropening in the structure of the manufacturing vessel 416 that would beknown by one having ordinary skill in the art to enable inner viewinfrared cameras 403 to measure the temperatures of the inner surface ofthe outer wall of manufacturing vessel 416.

Outer view infrared cameras 422 may be any infrared camera known tothose having ordinary skill in the art to be appropriate to image anouter surface of an outer wall of manufacturing vessel 416 when atemperature of manufacturing vessel 416 is elevated during theoperational cycle. Inner view infrared cameras 403 may be any infraredcamera known to those having ordinary skill in the art to be appropriateto image an inner surface of an outer wall of manufacturing vessel 416when a temperature of manufacturing vessel 416 is elevated during theoperational cycle.

The temperature data from outer view infrared cameras 422 and inner viewinfrared cameras 403 can be provided to computing complex 410 forsafekeeping in storage 414 and/or consideration by processor 412regarding the structural conditions of refractory lining 434. While ananalysis utilizing ASTM 680-14 or heat transfer calculation softwaredeveloped for refractory design may be used to calculate the temperaturedata obtained by outer view infrared cameras 422 in view of thermalresistivity and heat fluxes, embodiments disclosed herein are notlimited thereto. For example, any software or method of analysis knownto one having ordinary skill in the art to be able to calculate suchtemperature data can be utilized.

The temperature readings from inner view infrared cameras 403 during theoperational cycle may serve to complement the temperature readings fromenvironment measuring thermocouple 425 or non-metal measuringthermocouple 428.

As previously noted, when manufacturing vessel 416 is a glass melter ora similar vessel used for processing glass, radar/tomography scanningvia tomography sensors 411 may be used for measuring thickness ofrefractory lining 434, detecting incidence of glass impregnation intorefractory lining 434 during the operational cycle, or a combinationthereof. The radar/tomography measurement via tomography sensors 411 istaken from the outer surface of the outer wall of manufacturing vessel416. Tomography sensors 411 use radar wave technology to identify thedifference in density between the glass being processed during theoperational cycle and refractory lining 434.

Further, whether described above or below, the laser scanned data, thetemperature data, the radar data, the pressure data, the gas data, theglass pull rate data, or a combination thereof, which is communicated tocomputing complex 410 for consideration by processor 412, can beadditionally considered alongside of other measured and predeterminedoperational parameters stored in storage 414 that are awaitingcommunication to and consideration by processor 412. The measuredoperational parameters may be supplied to computer complex 410 forreference by processor 412 through previously discussed hardware means,including, but not limited to pressure sensors 407, gas sensors 409,auxiliary thermocouple 402, cycle time recording apparatus 423,tomography sensors 411, laser scanner 420, inner view infrared cameras403, outer view infrared cameras 422, auxiliary recording apparatus 424,environment measuring thermocouple 425, and non-metal measuringthermocouple 428. The predetermined operational parameters may besupplied to computer complex 410 through terminal 406 via user input orhistorical data previously processed by processor 412 and stored instorage 414 for future reference regarding the future status predictionfor refractory lining 434.

Predetermined operational parameters may include, but are not limitedto, historical data related to one or more refractories applied in oneor more historical refractory linings lined over inner surfaces of outerwalls of historical manufacturing vessels that handled non-metals, aninitial chemical composition and origin of refractory lining 434, aninitial physical design of refractory lining 434, a grade of thenon-metal that is desired to be produced during the operational cycle inmanufacturing vessel 416, physical and chemical attributes and amountsof charging or continuously fed mix components added to manufacturingvessel 416 during the operational cycle to produce the desired non-metalgrade and chemical attributes and amounts of additives, colorants orcombustion gases added to manufacturing vessel 416.

For purposes of this application, the physical design of refractorylining 434 may include, but is not limited to, construction details ofrefractory lining 434, shapes of refractory components in refractorylining 434, sizes of refractory components in refractory lining 434, andcombination of refractory components in refractory lining 434.

Additional measured operational parameters may include, but are notlimited to, a preheating, heat up, or cool down temperature and durationschedule according which manufacturing vessel 416 is being preheated orheated up prior to the operational cycle or cooled down after theoperational cycle. Further measured operational parameters may include acycle time defined by the cumulative duration of the operational cycle,or any other relevant measured operational parameter identified in aspecific non-metal producing operation.

Using the above-referenced data, processor 412 may determine an exposureimpact that the operational cycle has had on refractory lining 434 ofmanufacturing vessel 416 and predict a future status of refractorylining 434 after one or more subsequent operational cycles. The exposureimpact that the operational cycle has on refractory lining 434 may bedetermined by comparing the structural conditions of refractory lining434 before the operational cycle with the structural conditions ofrefractory lining 434 after the operational cycle. The future status ofrefractory lining 434 after one or more subsequent operational cycles ispredicted based on the determined exposure impact. In other words, theexposure impact of the initial cycle can be used to predict the futurestatus of refractory lining 434 after a second cycle, a third cycle, andso on. Processor 412 may consider data from all data sources referencedabove, but is not limited to thereto and could conceivably include otherdata sources not mentioned herein.

In one example, in order to supplement the prediction of the futurestatus of refractory lining 434, the determination of the exposureimpact of refractory lining 434 may also be supplemented by correlatingthe collected temperature data from outer view infrared cameras 422 andinner view infrared cameras 403 with the structural conditions ofrefractory lining 434 before, during, and after each operational cycle.This may allow the future status to be more accurately predicted.

In another example, in order to supplement the prediction of the futurestatus of refractory lining 434, the determination of the exposureimpact of refractory lining 434 may also be supplemented by considering,in correlation with the collected structural condition data, anoperational impact that one or more of the aforementioned predeterminedor measured operational parameters have on the exposure impact of theoperation cycle on refractory lining 434.

In one example, the historical data related to one or more refractoriesapplied in one or more historical refractory linings lined over innersurfaces of outer walls of historical manufacturing vessels thatproduced non-metal may be used to establish historical patterns ofexposure impact. Such historical patterns may complement the comparisonof the structural conditions of refractory lining 434 before and afterthe operational cycle of producing non-metal, as well as the correlationof the collected temperature data from outer view infrared cameras 422and inner view infrared cameras 403 therewith. Such historical datacould be amassed in storage 414 of computer complex 410 after exposureimpact determination to enable processor 412 to predict the futurestatus of subsequent refractory linings after each successiveoperational cycle with more accuracy.

With respect to the use of the measured operational parameters to assistin determination of the exposure impact, environment measuringthermocouple 425 can be provided to measure a temperature of theenvironment within manufacturing vessel 416. Non-metal measuringthermocouple 428 can be provided to measure a temperature of thenon-metal being processed within manufacturing vessel 416.

Moreover, auxiliary thermocouple 402 may be provided to measure atemperature of manufacturing vessel 416 when manufacturing vessel 416 isempty and being preheated or heated up prior to manufacturing vessel 416being filled of the non-metal, or during cooling down of manufacturingvessel 416 at the end of the operational cycle. Auxiliary thermocouple402, environment measuring thermocouple 425, and non-metal measuringthermocouple 428 may provide the measured temperature to computingcomplex 410 for consideration by processor 412 during the determinationof the exposure impact pursuant to the prediction of the future statusof refractory lining 434.

To monitor the cycle time duration, a recording mechanism, such as cycletime recording apparatus 423 featured herein, may be used to measure thecumulative contact duration during which the non-metal, the coatings, ora combination thereof are in contact with refractory lining 434 duringan operational cycle.

In addition, to monitor the duration of the preheating, or heat up, orcool down, a recording mechanism, such as auxiliary recording apparatus424 featured herein, may be used to control and record the duration andtemperature of the heating performed on manufacturing vessel 416 priorto an operational cycle, or cooling performed on manufacturing vessel416 at the end of the operational cycle. Specifically, the duration ofthe heating or cooling could be measured by auxiliary recordingapparatus 424 as being as little as a few hours and as great as severaldays. Auxiliary recording apparatus 424 may be included in a gas-poweredpreheater, along with an automatic gas shut-off.

Orientation laser 419 can be provided to scan manufacturing vessel 416to identify a physical orientation of manufacturing vessel 416 prior tothe laser scanning of refractory lining 434 by laser scanner 420. Thescanning performed by orientation laser 419 serves to assist andincrease the accuracy of the laser scanning of refractory lining 434performed by laser scanner 420. The physical orientation ofmanufacturing vessel 416 relates to the position of manufacturing vessel416 with respect to the process or facility in which manufacturingvessel 416 is being used. Orientation laser 419 provides the identifiedphysical orientation of manufacturing vessel 416 to computing complex410 for consideration by processor 412 to determine correct positioningof manufacturing vessel 416 for accurate determination of the exposureimpact pursuant to the prediction of the future status of refractorylining 434.

More particularly, data from orientation laser 419 may allow processor412 to determine thickness measurements from spatial measurements of thesurface of refractory lining 434. Such measurements cannot be derivedunless the physical location and orientation of manufacturing vessel 416is assumed or precisely known. Data from orientation laser 419 may allowprocessor 412 to precisely know the physical location and orientation ofmanufacturing vessel 416.

The orientation laser 419 can be positioned in any safe and unobstructedplace with a direct visibility of the outer wall of manufacturing vessel416, so that orientation laser 419 might be positioned to scan therelevant refractory lined portions of manufacturing vessel 416. It isalso noted that physical orientation identification by orientation laser419 can be supplemented through the data provided by laser scanner 420regarding manufacturing vessel 416.

Referring now to FIGS. 5 and 6, method 600 of predicting a future statusof refractory lining 434 that is lined over an inner surface of an outerwall of manufacturing vessel 416 and exposed to an operational cycleduring which refractory lining 434 is exposed to non-metal is described.

For purposes of discussion of method 600, “manufacturing vessel” mayrefer to a vessel, such as manufacturing vessel 416 that is exposed tonon-metal and an environment for processing or producing non-metal.Further, computing complex 410, including processor 412 and any othercontrol unit contained therein, is enabled to control all processes,including, but not limited to, scanning, measuring, transferringmaterials to and from manufacturing vessel 416, observing, collecting,determining, predicting, and considering.

In an example, manufacturing vessel 416 may be initially scanned byorientation laser 419 to identify a physical orientation ofmanufacturing vessel 416 prior to any scanning of refractory lining 434by laser scanners 420. The physical orientation of manufacturing vessel416 may be taken into account by processor 412 during any furtherconsiderations, determinations, and predictions by processor 412 withrespect to manufacturing vessel 416.

In addition, after physical orientation scanning and prior to anyscanning of refractory lining 434, while manufacturing vessel 416 isbeing preheated or heated up in preparation for an operation cycle, orcooled down after an operation cycle, a preheating temperature, a heatup temperature, or a cool down temperature, and a duration during whichmanufacturing vessel 416 is being preheated or heated up prior to theoperation cycle or cooled down after the operation cycle may be measuredby auxiliary thermocouple 402, and recorded by auxiliary apparatus 424.The temperature data and the preheating duration respectively collectedby auxiliary thermocouple 402 and auxiliary apparatus 424 may be used byprocessor 412 as measured parameters in considering an operationalimpact that the operational parameters related to the high-temperatureenvironment for producing a non-metal have on the structural conditionsof refractory lining 434 after exposure thereto.

Further measurement of operational parameters, such as, but not limitedto, a measurement of temperature of the non-metal in manufacturingvessel 416 by non-metal thermocouple 428, a measurement of temperatureof the environment in manufacturing vessel 416 by environment measuringthermocouple 425, and a measurement of the cumulative contact durationduring which the non-metal and the environment are in contact withrefractory lining 434 during the heat by cycle time recording apparatus423, may be performed during an operational cycle and will be describedin detail below. Predetermined operational parameters, as describedabove, may be provided to computing complex 410 when convenient.However, as has previously been noted and will be described furtherbelow, any predetermined operational parameters provided to computingcomplex 410 will be considered by processor 412 in the determination ofthe exposure impact on refractory lining 434.

After any additional preparative steps are completed, prior to anoperational cycle, a laser scan of refractory lining 434 ofmanufacturing vessel 416 is conducted (S601). The conducting of thelaser scan prior to the operational cycle may be performed by laserscanner 420. The conducting of the laser scan prior to the operationalcycle may also include the collecting of data related to pre-operationalcycle structural condition of refractory lining 434.

Then, an operational cycle is performed, during which manufacturingvessel 416 is filled with a high-temperature environment for producing anon-metal and, subsequently, a non-metal produced within thehigh-temperature environment. After the operational cycle is completed,another laser scan of refractory lining 434 of manufacturing vessel 416is conducted (S602). Similar to the conducting of the laser scan priorto the operational cycle, the conducting of the laser scan after theoperational cycle may be performed by laser scanner 420. Further, theconducting of the laser scan after the operational cycle may alsoinclude the collecting of data related to post-operational cyclestructural conditions of refractory lining 434.

After the laser scanning prior to the operational cycle and the laserscanning after the operational cycle, processor 412 determines (S603) anexposure impact of the operational cycle on refractory lining 434.Processor 412 may determine the exposure impact by comparing thecollected pre-operational cycle structural condition data with thecollected post-operational cycle structural condition data. After thedetermination of the exposure impact of the operational cycle, processor412 predicts (S604) the future status of refractory lining 434 after oneor more subsequent operational cycles based on the determination of theexposure impact of the operational cycle.

This prediction provides information that is crucial to determinewhether manufacturing vessel 416 can be used again with refractorylining 434 or if refractory lining 434 needs replaced. As such,accidents that result in excessive structural damage to themanufacturing vessel 416 can be avoided, resulting in less down time,greater efficiency, and cost savings.

In one example, during the operational cycle, one or more infrared scansof the outer surface of the outer wall of manufacturing vessel 416 maybe conducted by outer view infrared cameras 422. The scans enable outerview infrared cameras 422 to respectively collect data related to thetemperature of the outer surface detected during the operational cycle.This temperature data may be correlated with the collected structuralcondition data to more accurately determine the exposure impact andpredict the future status, while also identifying deteriorating portionsof refractory lining 434 based on the determined exposure impact.

In another example, the determining of the exposure impact includesconsidering, in correlation with the collected structural condition dataand, optionally, in this particular example, the collected temperaturedata from the infrared scanning, an operational impact that one or moreof the measured or predetermined operational parameters have onrefractory lining 434 during the operational cycle.

The predetermined operational parameters include those predeterminedoperational parameters previously discussed herein, including, but notlimited to, historical data related to one or more refractories appliedin one or more historical refractory linings exposed to thehigh-temperature environment and the non-metal, an initial chemicalcomposition and origin of refractory lining 434, an initial design ofrefractory lining 434, physical and chemical attributes and amounts ofcharging or continuously fed mix components added to manufacturingvessel 416 during the operational cycle, and a history of manufacturingvessel 416 during a period in which refractory lining 434 has been linedtherein.

The measured operational parameters include those measured operationalparameters previously discussed herein, including, but not limited to, apreheating, heating or cooling temperature and temperature changesmeasured by auxiliary thermocouple 402, a duration, during which changesin manufacturing vessel 416 measured by auxiliary thermocouple occurs,measured by auxiliary apparatus 424, a measurement of temperature of thenon-metal in manufacturing vessel 416 by non-metal measuringthermocouple 428, a measurement of temperature of the environment inmanufacturing vessel 416 by environment measuring thermocouple 425, ameasurement of the temperature of the inner surface of refractory lining434 by inner view infrared cameras 403, a measurement of the cumulativecontact duration during which the non-metal and the environment are incontact with refractory lining 434 during the operational cycle by cycletime recording apparatus 423, pressure and gas-type measurements withinmanufacturing vessel 416 respectively measured by pressure sensors 407and gas sensors 409, measuring thickness of refractory lining 434 viaradar/tomography scanning by tomography sensors 411, and glass pull ratemeasurements calculated by processor 412.

The foregoing description is a specific embodiment of the presentinvention. It should be appreciated that this embodiment is describedfor purposes of illustration only, and that numerous alterations andmodifications may be practiced by those skilled in the art withoutdeparting from the spirit and scope of the invention. It is intendedthat all such modifications and alterations be included insofar as theycome within the scope of the invention as claimed or the equivalentsthereof.

Having described the invention, the following is claimed:
 1. Ameasurement apparatus for predicting a future status of a refractorylining that is lined over an inner surface of an outer wall of amanufacturing vessel and exposed to an operational cycle, the apparatuscomprising: one or more laser scanners configured to conduct: one ormore pre-operational laser scans of the refractory lining prior to theoperational cycle to collect data related to pre-operational cyclestructural conditions; and one or more post-operational laser scans ofthe refractory lining after the operational cycle to collect datarelated to post-operational cycle structural conditions of therefractory lining; and a processor configured to: determine an exposureimpact of the operational cycle on the refractory lining by comparingthe collected pre-operational cycle structural condition data with thecollected post-operational cycle structural condition data; and predictthe future status of the refractory lining after one or more subsequentoperational cycles based on the determined exposure impact of theoperational cycle.
 2. The apparatus according to claim 1, furthercomprising: one or more outer view infrared cameras configured toconduct one or more infrared scans of an outer surface of the outer wallof the manufacturing vessel during the operational cycle to collecttemperature data related to a temperature of the outer surface duringthe operational cycle, wherein the processor is further configured todetermine the exposure impact by correlating the collected temperaturedata of the outer surface with the collected structural condition data,and wherein the processor is further configured to map the collectedtemperature data to identify deteriorating portions of the refractorylining.
 3. The apparatus according to claim 1, wherein the processor isfurther configured to determine the exposure impact by considering, incorrelation with the collected structural condition data, an operationalimpact that one or more operational parameters have on the refractorylining during the operational cycle, and wherein the operationalparameters include one or more predetermined operational parametersselected from the group consisting of: historical data related to one ormore refractories applied in one or more historical refractory linings;an initial chemical composition and origin of the refractory lining; aninitial refractory lining physical design; physical and chemicalattributes and amounts of charging components or continuously fed mixcomponents added to the manufacturing vessel during the operationalcycle; and a history of the manufacturing vessel during a period inwhich the refractory lining has been lined over the inner surface of theouter wall of the manufacturing vessel.
 4. The apparatus according toclaim 3, further comprising: an auxiliary thermocouple configured tomeasure a preheating, heating up, or cooling down duration during whichthe manufacturing vessel is being preheated or heated up prior to theoperational cycle or cooled down after the operational cycle, thepreheating or heating up or cool-down duration being one of theoperational parameters.
 5. The apparatus according to claim 3, furthercomprising: a cycle time recording apparatus configured to measure acumulative contact duration during the operation cycle in which therefractory lining is exposed to a high-temperature environment, thecumulative contact duration being one of the operational parameters. 6.The apparatus according to claim 3, further comprising: one or moreenvironment measuring thermocouples configured to measure a temperatureof a high-temperature environment in the manufacturing vessel during theoperational cycle, the measured high-temperature environment temperaturebeing one of the operational parameters.
 7. The apparatus according toclaim 1, further comprising: an orientation laser configured to scan themanufacturing vessel to identify a physical location and orientation ofthe manufacturing vessel prior to the operational cycle.
 8. Theapparatus according to claim 1, further comprising: one or moretomography sensors configured to conduct one or more tomography scans ofthe manufacturing vessel from the outer surface of the outer wall of themanufacturing vessel during the operation cycle to collect tomographydata related to one or more of a thickness of the refractory liningduring the operational cycle, wherein the processor is furtherconfigured to determine the exposure impact by correlating the collectedtomography data with the collected structural condition data.
 9. Amethod of predicting a future status of a refractory lining that islined over an inner surface of an outer wall of a manufacturing vesseland exposed to an operational cycle, the method comprising: conductingone or more pre-operational laser scans of the refractory lining priorto the heat, the conducting prior to the operational cycle to collectdata related to pre-operational cycle structural condition; conductingone or more post-operational laser scans of the refractory lining afterthe operational cycle to collect data related to post-operational cyclestructural conditions of the refractory lining; determining, via aprocessor, an exposure impact of the operational cycle on the refractorylining by comparing the collected pre-operational cycle structuralcondition data with the collected post-operational cycle structuralcondition data; and predicting, via the processor, the future status ofthe refractory lining after one or more subsequent operational cyclesbased on the determined exposure impact of the operational cycle. 10.The method according to claim 9, further comprising: conducting one ormore infrared scans of an outer surface of the outer wall of themanufacturing vessel during the operational cycle to collect datarelated to a temperature of the outer surface during the operationalcycle, wherein the determining of the exposure impact further comprises:correlating the collected temperature data of the outer surface with thecollected structural condition data; and mapping the collectedtemperature data to identify deteriorating portions of the refractorylining.
 11. The method according to claim 9, wherein the determining ofthe exposure impact further comprises considering, in correlation withthe collected structural condition data, an operational impact that oneor more operational parameters have on the refractory lining during theoperational cycle, wherein the operational parameters include one ormore predetermined operational parameters selected from the groupconsisting of: historical data related to one or more refractoriesapplied in one or more historical refractory linings; an initialchemical composition and origin of the refractory lining; an initialrefractory lining physical design; physical and chemical attributes andamounts of charging components or continuously fed mix components addedto the manufacturing vessel during the operational cycle; and a historyof the manufacturing vessel during a period in which the refractorylining has been lined over the inner surface of the outer wall of themanufacturing vessel.
 12. The method according to claim 11, furthercomprising: measuring a preheating, heating up, or cooling down,duration during which the manufacturing vessel is being preheated orheated up prior to the operational cycle or cooled down after theoperational cycle, the preheating or heating up or cool-down durationbeing one of the operational parameters.
 13. The method according toclaim 11, further comprising: measuring a cumulative contact duration ofthe operation cycle in which the refractory lining is exposed to ahigh-temperature environment, the cumulative contact duration being oneof the operational parameters.
 14. The method according to claim 11,further comprising: measuring a temperature of a high-temperatureenvironment in the manufacturing vessel during the operational cycle,the measured high-temperature environment temperature being one of theoperational parameters.
 15. The method according to claim 9, furthercomprising: conducting one or more tomography scans of the manufacturingvessel from the outer surface of the outer wall of the manufacturingvessel during the operation cycle to collect tomography data related toone or more of a thickness of the refractory lining during theoperational cycle, wherein the determining of the exposure impactfurther comprises correlating the collected tomography data with thecollected structural condition data.
 16. A measurement apparatus forpredicting a future status of a refractory lining that is lined over aninner surface of an outer wall of a manufacturing vessel and exposed toan operational cycle, the apparatus comprising: one or more laserscanners configured to collect data related to pre-operational cyclestructural conditions of the refractory lining prior to the operationalcycle and post-operational cycle structural conditions of the refractorylining after the operational cycle; and a processor configured to:determine an exposure impact of the operational cycle on the refractorylining by comparing the collected pre-operational cycle structuralcondition data with the collected post-operational cycle structuralcondition data; and predict the future status of the refractory liningafter one or more subsequent operational cycles based on the determinedexposure impact of the operational cycle.
 17. The apparatus according toclaim 16, further comprising: one or more infrared cameras configuredto, during the operational cycle, collect temperature data related to anouter surface of the outer wall; and wherein the processor is furtherconfigured to determine the exposure impact by correlating the collectedtemperature data of the outer surface with the collected structuralcondition data, and wherein the processor is further configured to mapthe collected temperature data to identify deteriorating portions of therefractory lining.
 18. A measurement apparatus for predicting a futurestatus of a refractory lining that is lined over an inner surface of anouter wall of a manufacturing vessel and exposed to an operationalcycle, the apparatus comprising: laser scanning means for collectingdata related to pre-operational cycle structural conditions of therefractory lining prior to the operational cycle and post-operationalcycle structural conditions of the refractory lining after theoperational cycle; and processing means for: determining an exposureimpact of the operational cycle on the refractory lining by comparingthe collected pre-operational cycle structural condition data with thecollected post-operational cycle structural condition data; andpredicting the future status of the refractory lining after one or moresubsequent operational cycles based on the determined exposure impact ofthe operational cycle.
 19. A measurement apparatus for predicting afuture status of a refractory lining that is lined over an inner surfaceof an outer wall of a manufacturing vessel and exposed to an operationalcycle, the apparatus comprising: means for collecting structuralcondition data related to pre-operational cycle structural conditions ofthe refractory lining prior to the operational cycle andpost-operational cycle structural conditions of the refractory liningafter the operational cycle; means for determining an exposure impact ofthe operational cycle on the refractory lining by comparing thecollected pre-operational cycle structural condition data with thecollected post-operational cycle structural condition data; and meansfor predicting the future status of the refractory lining after one ormore subsequent operational cycles based on the determined exposureimpact of the operational cycle.
 20. A method of predicting a futurestatus of a refractory lining that is lined over an inner surface of anouter wall of a manufacturing vessel and exposed to an operationalcycle, the method comprising: collecting structural condition datarelated to pre-operational cycle structural conditions of the refractorylining prior to the operational cycle and post-operational cyclestructural conditions of the refractory lining after the operationalcycle; determining an exposure impact of the operational cycle on therefractory lining by comparing the collected pre-operational cyclestructural condition data with the collected post-operational cyclestructural condition data; and predicting the future status of therefractory lining after one or more subsequent operational cycles basedon the determined exposure impact of the operational cycle.